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Fiat Tractor 55-60 60-90 79-90 80-90 90-90 100-90 tractor factory workshop manual download

Safety first
- Park on level ground, engine off, key out, wheels chocked, parking brake on. Wear gloves and eye protection. Support tractor securely if you remove covers or gearbox.

Overview of what you are adjusting and why
- The clutch must have a small pedal free travel so the release bearing is clear of the diaphragm/fingers when released, and enough travel when depressed to fully decompress the driven friction plate(s) so the gearbox input shaft is free.
- Too little free play (release bearing preloaded) → clutch drags, burns, hard gear changes, overheating.
- Too much free play → incomplete disengagement (gear grinding or inability to change gears smoothly) or clutch slip at load.
- Adjustment changes the effective length of the pedal-to-release mechanism (clevis/turnbuckle, cable, rod or hydraulic piston) so the release bearing contacts the diaphragm at the correct point and travel range is correct. If adjustment cannot restore correct geometry, friction plates or other parts are worn and must be serviced.

Step-by-step procedure (order you should follow) with theory and what the repair fixes

1) Preliminary checks and symptom-based diagnosis
- What to look for: clutch slip under load (engine revs rise without proportional ground speed), dragging (gear selection crunching, tractor moves with pedal fully up), abnormal pedal travel/hard or spongy pedal, noises.
- Why: distinguishing slip vs drag informs whether you adjust free play or investigate wear/hydraulics.

2) Identify whether clutch actuation is mechanical (rod/clevis/cable) or hydraulic
- Mechanical systems have an external adjusting turnbuckle or clevis at the pedal or bellhousing. Hydraulic systems use master/slave cylinders and are adjusted by fluid/bleeding (no external length adjuster).
- Why: adjustment method differs; mechanical systems are length adjustments, hydraulic require bleed/replace seals or adjust pedal stop.

3) Measure pedal free play and travel
- With engine off, measure pedal free travel (distance pedal moves before resistance/transfer to release bearing). Typical target range for many tractors: about 10–20 mm pedal free travel (0.4–0.8 in) and about 1–3 mm internal bearing clearance before the diaphragm is contacted. Use the tractor manual for exact spec.
- Why: confirms whether clutch is preloaded or has excessive slack. This is the datum you will correct.

4) Adjusting a mechanical clutch (rod/clevis/turnbuckle/cable)
A) Pedal-side adjustment (clevis/turnbuckle)
- Loosen locknut, turn adjuster to set pedal free travel to the target. Tighten locknut.
- Theory: lengthening the pushrod reduces free travel (pushes bearing closer), shortening increases free play. You set the rod length so the release bearing sits a few mm from the diaphragm when pedal is up.

B) Bellhousing/cable bracket adjustment (if present)
- Some tractors have adjuster at bellhousing or cable bracket. Adjust until bearing clearance or pedal free play meets spec. Lock off adjuster.
- Theory: same principle—adjusts preload on diaphragm/fingers and available disengagement travel.

C) Pedal-stop adjustment
- Set the pedal stop so pedal fully returns while leaving the correct free play; do not rely on hydraulic pressure to set free play.
- Theory: prevents over-setting the pedal travel that would keep bearing engaged.

What this fixes: Correcting the rod/cable length eliminates preloading or slack so the clutch fully engages (no drag) and fully disengages (smooth gear changes). If slip persists after correct geometry, friction linings are likely thin.

5) Adjusting a hydraulic clutch
- Check master/slave fluid level and bleed air from the system (bleed the circuit until pedal response is firm and travel matches spec). Inspect for leaking cylinders or rubber failure. Replace seals/cylinders if bleeding does not restore correct travel.
- Theory: air or fluid loss increases pedal travel and prevents full release; leaking seals allow bearing not to move to the correct position.

What this fixes: Restores correct actuation stroke so the release bearing and diaphragm operate in their designed range. Replaces hydraulic parts if internal leaks mean the system cannot keep the piston in correct position.

6) Functional test after adjustment (static tests)
- With engine idling, put gearbox in gear while holding brakes and lift the drawbar lightly — verify clutch fully disengages (no transfer of drive). Depress pedal and check full disconnection, then release and check for drag/creep.
- Theory: confirms the adjustment produced full mechanical separation between engine and gearbox at idle, and full re-engagement when released.

7) Road/test under load
- Drive under normal load and check for slip (engine revs rise without speed increase), overheating smell, smoke or clutch slip under load. Check gear changes for crunching (incomplete disengagement).
- Theory: real-world load verifies both engagement torque capacity and complete disengagement under gear change conditions.

8) When adjustment does not solve the fault — inspect clutch wear and internal geometry
- Remove access covers or split gearbox as required. Inspect friction plate(s) thickness, pressure plate runout, diaphragm fingers and release bearing condition. Measure friction disc thickness and axial clearance against specs. Check for glazed or burnt linings, oil contamination, or a bent/warped pressure plate.
- Theory: worn friction material reduces the distance the pressure plate must travel to clamp the disc(s); the release mechanism may run out of adjustment range (you can’t increase travel enough to take up wear). Also oil on discs prevents friction and causes slip regardless of adjuster position.

9) Repair/replace components if wear or contamination found
- Replace friction disc(s), pressure plate, release bearing and pilot bearing as necessary. Clean bellhousing and mating surfaces; remove oil source (leaking crank seal or gearbox input seal) and replace seals. Reassemble and set adjustment to spec.
- Why the repair fixes it: Fresh friction surfaces restore correct axial stack height so the designed travel and clamp load are effective. New seals prevent contamination that caused slipping.

10) Final adjustment and break-in
- After assembly set pedal free travel to spec again, torque locknuts. Break-in new clutch parts per manual (light load for a period). Recheck and fine-adjust after initial hours.
- Theory: new parts settle, and minor further adjustment is often needed to maintain correct free play as the linings bed in.

Common faults and how adjustment/repair fixes them (summary)
- Symptom: clutch drags (tractor moves with pedal up, hard gear shifts) → Cause: too little pedal free play or release bearing preloaded, or warped pressure plate or linkage stuck. Fix: lengthen pushrod/adjust clevis or repair binding linkage; if binding/warp remains, replace parts.
- Symptom: clutch slips under load (engine revs without speed, smoke) → Cause: excessive free play, worn/thin friction discs, oil contamination, weak springs. Fix: reduce free play (shorten rod) if adjustment range allows; if still slips, replace discs or remove contamination and repair seals.
- Symptom: spongy pedal, long travel, incomplete disengagement → Cause: hydraulic air/leak or worn mechanical linkage. Fix: bleed hydraulic system or adjust/repair linkage.
- Symptom: no adjustment left (you’re at either extreme of adjuster) → Cause: wear beyond compensation. Fix: strip and replace clutch pack and associated seals.

Practical tips (brief)
- Always set pedal free play first before trying other adjustments.
- Never preload the release bearing (no permanent contact with diaphragm/fingers). That causes rapid bearing and diaphragm wear.
- If you replace discs, always inspect/replace release bearing and pilot bearing; oils contaminate new linings quickly.
- Use manual specs for exact free travel, bearing clearance and torque; if you lack specs, aim for about 10–20 mm pedal free travel and 1–3 mm internal clearance as a starting point, then validate with functional tests.

This procedure and the underlying theory apply to the Fiat tractors you listed — the mechanics are the same: set correct free play/clearance so the release bearing only contacts the diaphragm when you press the pedal and the clutch plates have enough clamp travel to transmit torque. If adjusting the linkage/hydraulics cannot restore correct behavior, wear or contamination is the cause and the clutch pack or seals must be replaced.
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